High-temperature packaging of bone in meat product

ABSTRACT

Methods and apparatuses for preparing a ribbed meat product in a reduced cook cycle. The methods may comprise placing a ribbed meat product into a high-temperature cook-in bag suitable for high-temperature cooking processes that occur at temperatures greater than about 350° F. and sealing the high-temperature cook-in bag to create a package. The high-temperature cook-in bag containing the ribbed meat product may be placed directly into an oven and exposed to a temperature greater than about 350° F., reducing the cook time necessary to render or rethermalize the ribbed meat product by a factor of about 3 as compared to conventional low temperature cooking processes. The benefits of the disclosed methods include reduced cook times to render or rethermalize ribbed meat products, enhanced flavor of the ribbed meat products, reduced risk of contamination, and improved cleanliness. Both cooked and uncooked ribbed meat products may be prepared in these methods.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims benefit under 35 U.S.C. §119(e) of provisionalU.S. Patent Application No. 61/007,226, filed Dec. 11, 2007 and entitled“HIGH-TEMPERATURE PACKAGING OF BONE IN MEAT PRODUCT,” the disclosure ofwhich is incorporated herein by reference in its entirety.

TECHNOLOGY FIELD

The present invention relates generally to methods for preparing bone inmeat products in a reduced cook cycle using high-temperature cook-inbags. This technology is particularly well suited, but by no meanslimited, for preparing ribbed meat products in a reduced cook cycle.

BACKGROUND

Bone in meat products, including, for example, ribbed meat products, aretraditionally cooked in a two step process. First, the bone in meat isrendered to loosen the meat from the bone and to melt away portions ofthe fat. Following rendering, the bone in meat is put onto a grill, orsome other cooking appliance, to enhance the appearance and flavor ofthe meat, and to optionally caramelize a sauce on top of the bone inmeat.

Rendering is usually performed by boiling or roasting the bone in meatproduct. Various problems are associated with these traditionaltechniques. These problems exist on both a consumer level, such as asingle end user or a food service facility including restaurants,schools, institutions, etc., and a producer level. On the consumerlevel, the consumer is forced to choose between a flavorful meat or ashort cook time. For example, if the consumer decides to choose aflavorful meat, the meat must be rendered by slow roasting in an oven ata low temperature. The rendering process is extremely time consumingbecause very low temperatures must be employed (i.e. 200° F. to 250° F.)to ensure that the ribs remain moist and tender. If a higher temperatureis used to decrease the process time, the meat becomes dry, tough, andsticks to the bone. As such, rendering ribs by roasting in an oven at200° to 250° F. usually takes between about 3 and 4 hours.

If the consumer chooses a quicker method, such as boiling the bone inmeat products, flavor must be sacrificed. In the boiling method, thebone in meat is submerged into a pot of boiling water until the bone inmeat is sufficiently rendered. Although this technique is considerablyquicker than slow roasting, much of the flavor of the meat is lost inthe boiling water, resulting is a less flavorful end product.

These consumer problems lead further to market disadvantages for meatproducers. For example, because few consumers have the time to properlyprepare ribbed meat products, the market for these products is small. Assuch, meat producers usually view ribbed meat products as wasteproducts. Producers usually package and sell only a portion of theribbed meat products and the remaining supply is discarded once alleasily boned meat is removed. Accordingly, a method to prepare bone inmeat products, for example ribbed meat products, in a way that reducesthe cook time, and that does not diminish taste, would be desirable toboth consumers and producers.

SUMMARY

One aspect of the present invention concerns methods for preparing aribbed meat product in a reduced cook cycle comprising: placing, at aprocessor facility, an uncooked ribbed meat product into ahigh-temperature cook-in bag suitable for high-temperature cookingprocesses that occur at temperatures greater than about 350° F.;evacuating air from an inside of the cook-in bag; providing an oxygenbarrier to maintain shelf life of the uncooked ribbed meat productcontained within the cook-in bag; and hermetically and vacuum sealingthe high-temperature cook-in bag to create a contained packagecontaining the uncooked ribbed meat product. The high-temperaturecook-in bag containing the uncooked ribbed meat product may be placeddirectly into an oven. The contained package may be exposed to atemperature greater than about 350° F. thus reducing the cook timenecessary to render the ribbed meat product by a factor of about 3 ascompared to conventional low temperature cooking processes. In certainembodiments, the cook cycle may comprise a time period of about 1 hour.

The methods may further comprise freezing the contained package toproduce a frozen contained package, wherein the frozen contained packageis suitable for direct placement into a high-temperature cookingapparatus. The cooking apparatus may be an oven having a temperaturesetting of greater than about 350° F.

The high-temperature cook-in bag may comprise a blended monolayer filmcomprising nylon 6 and heat stabilized nylon 6,6. A suitable blendedmonolayer comprises from about 60% to about 80% nylon 6 and from about20% to about 40% heat stabilized nylon 6,6. Preferably, the blendedmonolayer comprises about 80% nylon 6 and about 20% heat stabilizednylon 6,6. In another embodiment, the high-temperature cook-in bag maycomprise a multi-layer film, wherein the multi-layered film comprises anouter layer and an inner layer. The multi-layer may further comprise atie layer between the outer layer and inner layer.

Methods of the present invention may further comprise preparing theuncooked ribbed meat product prior to placing the uncooked ribbedproduct into the high-temperature cook-in bag. Preparing may comprisetenderizing, seasoning, marinating and/or a combination thereof.

Methods may further comprise reducing the likelihood of contamination ofthe ribbed meat product and/or transfer of bacteria from the ribbed meatproduct to humans by fully containing the ribbed meat product within thehigh-temperature cook-in bag from placement of the ribbed meat productin the cook-in bag at the processor facility until after rendering ofthe ribbed meat product in a high-temperature apparatus. In oneembodiment, the methods may comprise retaining moisture and flavor ofthe ribbed meat product by containing the juices from the ribbed meatproduct within the contained package.

In one embodiment, the methods may comprise venting of thehigh-temperature cook-in bag. The methods may further comprisehermetically sealing the contained package under vacuum. Thehigh-temperature cooking bags utilized in the methods of the presentinvention may have a tear resistance of greater than about 50 g/mil toreduce tearing or puncturing of the cook-in bag by the ribbed meatproduct during transportation of the contained package.

Another aspect of the present invention concerns methods for preparing aribbed food product in a reduced cook cycle comprising: placing, at aprocessor facility, a substantially fully cooked ribbed meat productinto a high-temperature cook-in bag suitable for high-temperatureprocesses that occur at temperatures greater than about 350° F.;providing an oxygen barrier to maintain shelf life; and hermeticallysealing the high-temperature cook-in bag to create a contained packagecontaining the substantially fully cooked ribbed meat product. Thecontained package may be exposed to a temperature greater than about350° F., thus reducing the cook time necessary to rethermalize theribbed meat product. The cooked ribbed meat product may be preparedprior to placing the cooked ribbed product into the high-temperaturecook-in bag. The methods may further comprise freezing the containedpackage to produce a frozen contained package, wherein the frozencontained package is suitable for direct placement into ahigh-temperature cooking source. The contained package of the currentmethods may be hermetically sealed under vacuum. Further, methods maycomprise transporting the contained package.

Another aspect of the present invention may comprise methods forpreparing a ribbed food product in a reduced cook cycle comprising:placing an uncooked ribbed food product into a high-temperature cook-inbag; closing the high-temperature cook-in bag to create a sealed packagecomprising the uncooked ribbed food product; and reducing the cook timeto render the ribbed food product by exposing the sealed package to atemperature greater than about 350° F. The cook cycle may comprise about1 hour. Further, the cook cycle may be reduced by a factor of three overconventional rendering methods. The current methods may provide for thejuices from the ribbed meat product to remain within the sealed package,thereby retaining moisture and flavor of the ribbed meat product.

Methods of the present invention may convert the rendering of bone inmeat products from a low temperature, long cook cycle process into ahigh-temperature short cook cycle process, essentially turning bone inmeat products into a convenience food.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing and other aspects of the present invention will becomeapparent from the following detailed description of the invention whenconsidered in conjunction with the accompanying drawings. For thepurpose of illustrating the invention, there is shown in the drawingsembodiments that are presently preferred, it being understood, however,that the invention is not limited to the specific instrumentalitiesdisclosed. In the drawings:

FIGS. 1A and 1B are top and side views, respectively, of an exemplarycontained package comprising a high-temperature cook-in bag and a ribbedmeat product;

FIG. 1C is a side view of an exemplary contained package comprising ahigh-temperature cook-in bag and a ribbed meat product, under vacuum;

FIGS. 2A and 2B are top and side views, respectively, of an exemplaryhigh-temperature cook-in bag used to prepare a ribbed meat product;

FIGS. 3A and 3B are top and side views, respectively, of an exemplaryhigh-temperature cook-in bag with a ribbed meat placed within;

FIG. 4 is a cross section view of an exemplary blended monolayer filmthat may be used in the formation of a high-temperature cook-in bag forpreparing ribbed meat products in a reduced cooking cycle;

FIG. 5 is a cross sectional view of an exemplary multilayer filmcomprising two layers that may be used in the formation of ahigh-temperature cook-in bag for preparing ribbed meat products in areduced cooking cycle;

FIG. 6 is a cross sectional view of an exemplary multilayer filmcomprising three layers that may be used in the formation of ahigh-temperature cook-in bag for preparing ribbed meat products in areduced cooking cycle;

FIGS. 7A and 7B are top and side views, respectively, of an exemplarymethod for packaging and preparing a ribbed meat product; and

FIG. 8 is a side view schematic of an exemplary process for makinghigh-temperature cook-in bags that may be used in the methods of thepresent invention.

DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS

The present invention is directed to methods for the preparation of bonein meat products in a reduced cook cycle. Bone in meats, may include forexample, fowl, fish, lamb, pork, beef, among others. Suitable bone inmeat products may include hams, pork shoulders, etc. The presentinvention is particularly well-suited for preparing ribbed meatproducts. Suitable ribbed meat products can include, for example, porkand beef products including rib roasts, pork chops, spareribs, baby backribs, St. Louis style spareribs, country style spareribs, Kansas Citystyle ribs, riblets, rib tips, and the like.

As used herein, a cook cycle may be defined as the period of timerequired to at least substantially cook a bone in meat product, render abone in meat product, or reheat a bone in meat product. The methods ofthe present invention provide several advantages over current methods toprepare bone in meat products. For example, cooking cycles required torender ribbed meat products using the methods of the present inventionare dramatically reduced. In some embodiments, the cooking cycle torender the ribbed meat product is reduced by a factor of three. In otherembodiments, the cooking cycle to render the ribbed meat product is lessthan about one hour. The reduced cook cycle afforded by thehigh-temperature cook-in bag provides a marked advantage overconventional low temperature methods of cooking ribbed meat products,which typically take place at 200° F. to 250° F. and take as long as 3-4hours or more.

Other benefits of the present invention include increased flavorassociated with the cooked bone in meat product, retained moistureduring the cooking process, lower risk of cross-contamination betweenthe bone in meat product and humans, and easier cleanup after thecooking process is complete. These benefits are afforded through theplacement of bone in meat products, such as ribbed meat products, intohigh-temperature cook-in bags and subsequently sealing thehigh-temperature cook-in bags to form a contained package. Thehigh-temperature cook-in bags may be any type of enclosure, container,package, pouch, rollstock, tube, form-fill-seal films, etc., suitablefor receiving bone in meat products.

FIGS. 1A and 1B are top and side views, respectively, of a containedpackage 10A having an exemplary high-temperature cook-in bag 10. Asshown in FIGS. 1A and 1B, the contained package 10A may include thehigh-temperature cook-in bag 10 with a ribbed meat product 300 disposedtherein. The high-temperature cook-in bag 10 may include ends 13, 14,which may be closed or sealed after the ribbed meat product is disposedin the high-temperature cook-in bag 10. FIG. 1C is a side view of thecontained packaged 10A sealed under vacuum, which may improve theshelf-life of the ribbed meat product 300.

FIGS. 2A and 2B are top and side views, respectively, of thehigh-temperature cook-in bag 10 prior to insertion of the ribbed meatproduct 300. The high-temperature cook-in bag 10 may be comprised of ahigh-temperature film 100, and may include at least one side wall 11 andthe ends 13, 14. The high-temperature cook-in bag 10 may define a cavity12. As shown in FIG. 2B, the end 13 of the high-temperature cook-in bag10 may be closed and the end 14 of the high-temperature cook-in bag 10may define an opening 15 into the cavity 12 for receiving the ribbedmeat product 300.

FIGS. 3A and 3B are top and side views, respectively, of thehigh-temperature cook-in bag 10 with the ribbed meat product 300inserted in the cavity 12 through the opening 15. After the ribbed meatproduct 300 is inserted into the cavity 12, the end 14 may be closed toform a contained package 10A that includes the ribbed meat product 300.For example, opening 15 may be closed using a seal 17, such as a heatseal. In certain embodiments, the air inside the bag may be evacuatedduring the sealing process, as shown in FIG. 1C for example.

As used herein, high-temperature may refer to temperatures greater thanabout 350° F. The high-temperature cook-in bag 10 utilized in thepresent invention may comprise a blended monolayer film or may comprisemultilayer films comprising materials that can withstandhigh-temperatures and may also have other beneficial properties such asthe ability to be readily heat sealed, durability, good moisture barrierproperties, and/or good gas barrier properties. Suitable films for usewith embodiments of the present invention are described in U.S.Provisional Patent Application No. 60/973,961, filed on Sep. 20, 2007,and U.S. patent application Ser. No. 12/233,319, filed on Sep. 18, 2008,the disclosures of which are incorporated herein by reference in theirentireties. Furthermore, high-temperature thermoformed webs may also beutilized in the methods of the present invention. Suitable thermoformedwebs and suitable films comprised in suitable thermoformed webs aredescribed in U.S. Provisional Patent Application No. 60/973,963, filedon Sep. 20, 2007, and U.S. patent application Ser. No. 12/233,204, filedon Sep. 18, 2008, the disclosures of which are incorporated herein byreference in their entireties.

The high-temperature cook-in bag 10 utilized in certain embodiments ofthe present invention may also be readily heat sealed on conventionalheat seal equipment that exists in meat packing plants. Furthermore, thehigh-temperature cook-in bag 10 may have better tear strength andpuncture resistance than the traditional cook-in bags, and may be frozenand shipped with improved tear strength and puncture resistance. Thehigh-temperature cook-in bag 10 may also have improved gas and/ormoisture barrier properties over conventional cook-in bags.

The film for the high-temperature cook-in bag 10 may be produced usingany technology known to one skilled in the art of high-temperaturecook-in bag production. Suitable technologies include blown filmtechnology (both mono-layer and co-extrusion), cast film technology(both mono-layer and co-extrusion), or biaxial orientation(double-bubble or tenter frame, mono-layer or co-extrusion). The filmcan be either shrink or non-shrink. Typical film thickness may be fromabout 1 mil to about 6 mils. Preferably, film thickness may be fromabout 3 mils to about 4 mils.

The high-temperature films employed in the present invention may have aninterior surface and an exterior surface. The interior surface is theportion of the high-temperature film that is in contact with the ribbedmeat product. The exterior surface is the outside of thehigh-temperature film. Preferably the interior surface is comprised of acomposition that does not stick to meat.

Several materials may be used to construct high-temperature films foruse in high-temperature cook-in bag 10 for rending ribbed meat productsin reduced cooking cycles. Suitable materials may have one, if not more,of the following characteristics. These characteristics include: highmelting point, can be readily heat sealed, good tear strength/punctureresistance, can withstand being frozen, shipped, etc., and good barrierproperties, such as gas and/or moisture barrier properties. Suitablematerials include polyester elastomer, polyamide elastomer, nylon,polyester, and polypropylene.

One characteristic for a suitable material is good barrier propertiessuch as gas and moisture. As used herein, a material with a suitable gasbarrier property has an oxygen barrier transmission coefficient ofapproximately 30 cc/24 hr/100 in2/mil. Preferably, the oxygen barriertransmission coefficient is at least approximately 10 cc/24 hr/100in2/mil. As used herein, a material with a suitable moisture barrierproperty has a water vapor barrier transmission coefficient ofapproximately 40 g/24 hr/100 in2/mil. Preferably, the water vaporbarrier transmission coefficient is approximately 10 g/24 hr/100in2/mil.

Another characteristic for a suitable material is good tear strength. Asused herein, a material with good tear strength has a tear strengthgreater than about 50 g/mil. In a more preferred embodiment, a materialwith a good tear strength has a tear strength of greater than about 75g/mil. A suitable material may also have a good tensile yield strength.As used herein, a material with a good tensile yield strength has atensile yield strength of greater than approximately 2,000 psi.Preferably, the tensile yield strength is greater than approximately2,500 psi. In certain embodiments, the tear strength, punctureresistance, and tensile yield strengths of the film are improved throughthe combination of multiple layers in a multi-layer film.

A further characteristic for a suitable material is one thatsubstantially does not adhere to ribbed meat products during or afterthe cooking of ribbed meat products. As used herein, substantially doesnot adhere to ribbed meat products may be defined as less than about 5%weight of the ribbed meat product sticking to the package.

Homopolymer nylon is a suitable material for a layer within ahigh-temperature multilayer film. Nylon has exceptional oxygen, carbondioxide and nitrogen barrier properties. Accordingly, it can be used asa barrier layer in a film structure that will maintain a vacuum or couldbe used in a gas flush package.

Nylon can be used as a layer by itself, or can be blended with othermaterials to form a layer. Suitable materials that can be blended withnylon include, polyester, polyamide elastomer, and polyester elastomer.Suitable nylon includes AKULON®, AKULON® F136 C1 which is a nylon 6,ULTRAMID®, ULTRAMID B40 LN01 which is a nylon 6, BASF B40LN01, which isa nylon 6, ASCEND®, SOLUTIA 66J, which is a nylon 6,6 containing a heatstabilizer, and UTRAMID C33, which is a nylon 6,6/6 co-polymer. Further,various nylons may be blended together to form a blended monolayer. Forexample, nylon 6 may be blended with a heat stabilized nylon 6,6.

In certain embodiments, heat stabilizers may be added to the nylon toimprove its heat stability. Although nylon has a relatively high meltpoint, approximately 423° F., without the addition of a heat stabilizer,nylon may become brown and brittle at temperatures higher thanapproximately 325° F. Suitable heat stabilizers may include copper saltssuch as copper iodide, copper bromide, and copper acetate.

When producing multi-layers films, it may be desirable to combine layersusing a method that does not decrease the bags ability to be used forhigh-temperature cooking. A suitable method to accomplish this isthrough the use of a tie layer. A tie layer may be an intermediate layerbetween two layers of dissimilar materials. The tie layer may becomprised of materials of the layers in which it is between. Thiscomposition facilitates good adhesion of the layers because each layeris attached to a layer comprised, at least in part, of like materials.For example, to join a polyester layer with a nylon layer, a tie layercomprising a polyester elastomer blended with nylon would be suitable.

In certain embodiments, layers comprise a blend of a base material, suchas polyester or nylon, with an elastomeric material such as polyesterelastomer or polyamide elastomer. Preferably, the percentage of basematerial in a layer is at least about 75% (by weight). In otherembodiments, the percentage of base material in a layer is at leastabout 80% (by weight). In other embodiments, the percentage of basematerial in a layer is at least about 90% (by weight).

FIG. 4 is a cross-sectional view of an exemplary high-temperature film100 a used in embodiments of the high-temperature cook-in bag 10 of thepresent invention. As shown, the film 100 a may include a blendedmonolayer 1 a with an exterior 20 a and an interior 30 a. The blendedmonolayer film 100 a may comprise a blend of nylon 6 and heat stabilizednylon 6,6. In certain embodiments, the blended monolayer film 100 a maycomprise from between about 60% and about 80% nylon 6 and from about 20%to about 40% heat stabilized nylon 6,6. Preferably, the blendedmonolayer film 100 a may comprise about 80% nylon 6 and about 20% heatstabilized nylon 6,6. The blended monolayer film 100 a has severaladvantages over traditional monolayer films. For example, the nylonblend has superior oxygen barrier properties providing improved shelflife of the ribbed meat product 300. Further, the blended monolayer film100 a is very durable and has suitable tear and puncture resistance towithstand shipping/storing applications. Most notably, however, is theability of the blended monolayer film 100 a to withstandhigh-temperatures. For example, the blended monolayer film 100 a maywithstand temperatures greater than about 350° F., and for example,temperatures greater than about 400° F.

FIG. 5 is a cross-sectional view of an exemplary multilayer film 100 bthat may be used in the formation of the high-temperature cook-in bag10. The multilayer film 100 b may comprise an exterior 20 b and aninterior 30 b. FIG. 5 shows a two layer structure, i.e., an outer layer1 b and an inner layer 2 b. The outer layer 1 b of the film 100 b(outside of the bag) may be a blend of two materials. Suitable materialsfor the outer layer 1 b include a polyester blended with eitherpolyester elastomer or polyamide elastomer. Suitable materials for theinner layer 2 b (inside of the bag) include a polyester elastomer orpolyamide elastomer.

There are several advantages to the film structure shown in FIG. 5.First, because the inner layer 2 b of the bag 10 may be a polyester orpolyamide elastomer, it will not stick or have reduced adhesion to meatproteins during cooking. Also, the elastomer content provides goodpuncture resistance. Furthermore, the polyester provides suitablemoisture barrier properties. Finally, the polyester may be oriented.Orientation provides additional benefits including increased tearresistance and puncture resistance along with the ability for the bag tobe shrinkable.

Other suitable materials for the outer layer 1 b include nylon blendedwith a polyester elastomer or polyamide elastomer. The benefits of thistype of layer is that the outer layer 1 b possesses some of thebeneficial characteristics of a nylon layer, e.g., good gas barrierproperties, and some of the beneficial characteristics of a polyesterelastomer or polyamide elastomer layer, e.g., good flexibility.Furthermore, the polyester elastomer in the polyester elastomer/nylonblend of the outer layer 1 b has an affinity for the polyester elastomerinner layer 2 b. Suitable amounts of polyester elastomer in the outerlayer are less than about 25% (by weight). Preferably, the amount ofpolyester elastomer is less than about 20% (by weight).

FIG. 6 is a cross-sectional view of an exemplary multilayer film 100 cthat may be used in the formation of the high-temperature cook-in bag10. The multilayer film 100 c may comprise an exterior 20 c and aninterior 30 c. FIG. 6 shows a three layer structure comprising an outerlayer 1 c, an inner layer 2 c, and a middle layer 3 c. Suitablematerials for the outer layer 1 c include polyester elastomer, polyamideelastomer, or nylon. Suitable materials for the inner layer 2 c includepolyester elastomer or polyamide elastomer. Suitable materials for themiddle layer 3 c include a polyester blended with a polyester elastomeror a polyamide elastomer; or a nylon blended with a polyester elastomeror polyamide elastomer.

In one embodiment, the high-temperature cook-in bag 10 may be comprisedof the film 100 c wherein the outer layer 1 c comprises a polyesterelastomer or polyamide elastomer, the inner layer 2 c comprises apolyester elastomer or polyamide elastomer, and the middle 3 c layercomprises a polyester blended with a polyester elastomer or polyamideelastomer. The middle layer 3 c in this embodiment may serve as a tielayer between the outer layer 1 c and inner layer 2 c. Benefits includegood moisture barrier properties due to the presence of polyester in thefilm 100 c, reduced adhesion of meat products to the bag 10 due topolyester elastomer or polyamide elastomer as an inner layer, andincreased flexibility and durability because of the polyester elastomerlayers.

In another embodiment, the high-temperature cook-in bag 10 may becomprised of the film 100 c wherein the outer layer 1 e comprises nylon,the inner layer 2 c comprises a polyester elastomer or polyamideelastomer, and the middle layer 3 c comprises a nylon blended with apolyester elastomer or polyamide elastomer. The middle layer 3 c in thisembodiment may serve as a tie layer between the outer layer 1 c andinner layer 2 c. The benefits of this structure include superior gasbarrier properties due to the 100% nylon outer layer 1 c, improved heatseal qualities due to polyester elastomer or polyamide elastomer as theinner layer 2 c, reduced adhesion of meat products to the bag due topolyester elastomer or polyamide elastomer as the inner layer 2 c, andimproved bone puncture resistance due to the presence of polyesterelastomer and polyamide elastomer in the film 100 c.

FIGS. 7A and 7B are top and side views, respectively, of an exemplaryprocess for preparing a ribbed meat product. As shown in FIGS. 7A and7B, the high-temperature cook-in bag 10 may be manufactured from a sheetof film tube 200—Step 1. The film tube 200 may be in the form of a rollthat can be unrolled across a bag machine 800 (see FIG. 8.) to producehigh-temperature cook-in bags 10 utilized in the present invention. Thefilm tube 200 may be unrolled on an unwind stand 805. The film tube 200may be subsequently rolled through dancer rolls 810 to control thetension of the film tube roll as it moves along the bag machine 800.Individual compartments 130 may be formed from the film tube roll 200using various methods to produce the seal 17—Step 2. Suitable methods toseal the film tube roll 200 are known to one skilled in the art and mayinclude heat sealing, and ultrasonic welding, among others. In thisembodiment, the seals 17 are formed by heat sealing using a heated sealbar 820. The heat seal bar 820 melts the tubing by pressing the filmtube against a rubber roller 830. As the film tube progresses down thebag machine via nip rolls 840, the film tube 200 with the seals issubsequently cut 850 in a manner where the seal is only at the bottom ofthe bag 10 and the top portion of the bag 10 contains an opening. Theresultant high-temperature bag 10 for rending ribbed meat products 300in a reduced cook cycle can be seen in FIGS. 2A and 2B.

Once the bags 10 are formed, the ribbed meat product 300 may be placedinto the cook-in bag 10—Step 4 (see also FIGS. 3A and 3B). Suitableribbed meat products 300 are described herein and may be either cookedor uncooked when they are insert into the cook-in bag 10. Further, theribbed meat products 300 may be prepared prior to placement into the bag10. For example, the meat products 300 may be tenderized, seasoned,sauced, or any combination thereof. Also, various amounts of meatproducts 300 may be included into one bag 10. Depending upon theapplication, one or more ribbed meat products 300 may be placed into thebag 10. In one embodiment, two ribbed meat products 300 are placedwithin the bag 10. In another embodiment, three ribbed meat products 300are placed within the bag 10. As such, the size of the bag 10 may varydepending upon the application.

For example, to prepare a single riblet, a suitable high-temperaturecooking bag 10 may have a size of approximately 2 inches by 8 inches. Toprepare a bone in pork shoulder or ham, a suitable high-temperaturecooking bag 10 may have a size of approximately 16 inches by 30 inches.In one embodiment, a short rack of baby back ribs may be prepared in ahigh-temperature cook-in bag 10 with an approximate size of about 6inches by 20 inches. In other embodiments, the size of the bag 10 isabout 7 inches by 24 inches, or for example, about 9 inches by 28inches. Preferably, the size of the bag 10 is suitable to contain atleast one rack of ribs. In some embodiments, the bag 10 is suitable tocontain at least two racks of ribs. In another embodiment, the size ofthe bag 10 is suitable to contain at least three racks of ribs.

After the ribbed meat product 300 is placed inside the bag 10, air mayoptionally be evacuated 400 from the cook-in bag 10 and the bag 10 maybe closed by, for example sealing the bag closed—Step 5 (see seal 17).Air may be evacuated from the interior of cook-in bag 10 usingconventional methods known to one skilled in the art (e.g., a vacuum).Further, the cook-in bag 10 may be sealed using conventional methodsknown to one skilled in the art. For example, the cook-in bag 10 may besealed using a heat sealing technique. The resultant product is acontained package 10A (see FIGS. 1A-1C). Preferably, the bag 10 ishermetically and/or vacuum sealed to increase the shelf-life of theribbed meat product 300. Maintaining a vacuum within the sealed cook-inbag 10 helps ensure that there is none or only a negligible amount offree oxygen in the cook-in bag 10 and a hermetic seal helps ensure thatno or a negligible amount of oxygen may enter the cook-in bag 10 duringshipping and storage. Further, the films utilized to produce thehigh-temperature cook-in bags 10 of the present invention have very lowoxygen transmission coefficients. Thus, an oxygen barrier is providedwith this contained package 10A to increase shelf life of the ribbedmeat product 300.

In one embodiment, formation of the contained package 10A occurs at aprocessing facility. Once the contained package 10A is formed, thepackage 10A may subsequently be transported to another facility, such asa retail market. The films used to produce the bags 10 of the presentinvention provide for a durable bag with increased puncture/tearresistance. These durable bags 10 are able to withstand the rigor oftransport. Further, the contained package 10A containing the ribbed meatproduct 300 may be frozen or refrigerated in a freezer/refrigerator500—Step 6. This may occur either before or after transport. Thefrozen/refrigerated contained package 10A may subsequently be placeddirectly into a high-temperature heating apparatus 600—Step 7. Suitablehigh-temperature heating apparatuses 600 include ovens, microwaves,convection ovens, steam and pressure cookers, slow cookers, smokehouses, and vessels containing heat water, among others. Alternatively,the frozen/refrigerated contained package 10A may be removed from thefreezer or refrigerator and may be defrosted in a microwave prior tobeing placed into a high-temperature heating apparatus 600.Advantageously, embodiments of the present invention allow for theribbed meat product 300 to be sealed in a high-temperature cook-in bag10 to form a contained package 10A, frozen or refrigerated 500 in thatsame contained package 10A, and placed into a high-temperature heatingapparatus 600 in that same contained package 10A.

If the ribbed meat product 300 is cooked prior to placement into thehigh-temperature cook-in bag 10, the various benefits of the presentinvention still apply, however, rather than the ribbed meat product 300being cooked within the contained package 10A, the cooked ribbed meatproduct 300 may be rethermalized within the contained package 10A.Rethermalizing the ribbed meat product 300 according the methods of thepresent invention reduces the time required to accomplish therethermalizing due to the ability to apply a high-temperature, i.e.,greater than 350° F. Further, because the ribbed meat product 300 iscontained within the cook-in bag 10, the ribbed meat product 300 staysmoist and will not dry out. Further, the high-temperature cook-in bags10 of the present invention provide for an oxygen barrier, a hermeticseal, a vacuum seal or a combination thereof which improves theshelf-life of the ribbed meat product 300 as discussed herein.

In another embodiment of the present invention, the placement of theribbed meat product 300 into the high-temperature cook-in bag 10 isperformed after the ribbed meat product 300 has been shipped by the meatprocessor. This placement may be performed, for example, in aresidential kitchen, in a restaurant, in a cafeteria, etc. In thisembodiment, high-temperature cook-in bags 10 may be prepared usingmethods as discussed above. The ribbed meat product 300 may be placedinto the high-temperature cook-in bag 10 prior to being placed directlyinto the high-temperature heating apparatus 600. Suitablehigh-temperature heating apparatuses 600 include ovens, microwaves,convection ovens, steam and pressure cookers, slow cookers, smokehouses, and vessels containing heat water, among others. The ribbed meatproduct 300 may also be placed into the high-temperature cook-in bag 10and may subsequently be frozen/refrigerated. Following thefreezing/refrigeration process, the high-temperature cook-in bags 10containing the ribbed meat product 300 may be placed directly into ahigh-temperature heating apparatus 600.

The high-temperature cook-in bag 10 may include a closure system toprovide for a sufficient seal to contain the juices of the ribbed meatproduct 300 within the cook-in bag. The closure system is preferablysuitable for high-temperature applications. For example, the closuresystem may include a flap portion combined with an adhesive wherein theflap portion may be folded over the opening 15 in the bag 10 and theadhesive closes and seals the bag opening. The adhesive may be disposedon the flap portion and/or the portion of the bag opposite the flapwhere the flap portion folds over. The adhesive may be covered by anon-adhesive covering (e.g. tape) that covers and protects the adhesiveprior to use.

Alternatively, the oven bag closure system may include ahigh-temperature zip lock closure or “slider” closure substantially nearthe top open end of the bag 10. Such a closure may be made out of amaterial such as nylon or polyester. In another example, the closure bagsystem may include high-temperature snap fasteners substantially nearthe top open end 15 of the bag 10. Such snap fasteners may be welded onto a lip of the bag 10. The snaps may be made using well-knowntechniques in the art, such as injection molding the snaps out of nylonor polyester, for example.

There are several advantages to this embodiment over the current art.For example, this embodiment allows for ribbed meat products 300 to becooked in situations that were not possible prior to this invention.Previously, cooking ribbed meat products 300 at large functions wasimpractical due to the slow cook times. This invention, however, allowsfor consumers such as cafeterias, banquet facilities, and cateringfacilities, to prepare large quantities of ribbed meat products 300.This is provided, in part, because of the shorter cook times provided bythe present invention. The consumer may simply purchase the ribbed meatproducts 300, place the ribbed meat products 300 into thehigh-temperature cooking bags 10, and render the ribbed meat products300 in a reduced cook cycle.

Those skilled in the art will appreciate that numerous changes andmodifications may be made to the preferred embodiments of the inventionand that such changes and modifications may be made without departingfrom the spirit of the invention. It is therefore intended that theappended claims cover all such equivalent variations as fall within thetrue spirit of the invention.

1. A method for preparing a bone in meat product for a cook cycle, themethod comprising: placing the bone in meat product into ahigh-temperature cook-in bag comprising a film, wherein the film isconfigured to be exposed to a temperature of at least 350° F. during thecook cycle; and sealing the high-temperature cook-in bag to form apackage that includes the bone in meat product, wherein the filmincludes an oxygen barrier for maintaining a vacuum seal within thepackage.
 2. The method of claim 1, wherein the film is a blendedmonolayer film comprising at least 75% nylon blended with at least oneof a polyester, a polyamide elastomer, or a polyester elastomer.
 3. Themethod of claim 1, wherein film is a blended monolayer film comprisingabout 60% to 80% nylon 6 and about 20% to 40% heat-stabilized nylon 6,6.4. The method of claim 1, wherein the film is a multilayer filmcomprising an outer layer and an inner layer, wherein the outer layerincludes at least 75% nylon or polyester blended with a polyesterelastomer or a polyamide elastomer, and wherein the inner layer includesa polyester elastomer or polyamide elastomer.
 5. The method of claim 1,wherein the film is a multilayer film comprising an outer layer, aninner layer and a tie layer disposed between the outer and inner layers,wherein the outer layer includes a polyester elastomer, a polyamideelastomer, or a nylon, wherein the inner layer includes a polyesterelastomer or a polyamide elastomer, and wherein the tie layer includesat least 75% nylon or polyester blended with a polyester elastomer or apolyamide elastomer.
 6. The method of claim 1, wherein the film has athickness in a range of about 1 mil to 6 mils.
 7. The method of claim 1,wherein the film has an oxygen barrier transmission coefficientapproximately equal to, or less than, 30 cc/24 hr/100 in²/mil and awater vapor barrier transmission coefficient approximately equal to, orless than, 40 g/24 hr/100 in²/mil.
 8. The method of claim 1, wherein thefilm has a tear strength greater than about 50 g/mil and a tensile yieldstrength of greater than approximately 2,000 psi.
 9. The method of claim1, further comprising cooking or rendering the bone in meat productprior to placing the bone-in meat product in the high-temperaturecook-in bag.
 10. The method of claim 1, further comprising tenderizing,seasoning, or marinating the bone in meat product prior to placing thebone in meat product into the high-temperature cook-in bag.
 11. Themethod of claim 1, wherein sealing the high-temperature cook-in bagincludes evacuating air from the high-temperature cook-in bag andhermetically sealing the high-temperature cook-in bag.
 12. The method ofclaim 1, wherein the package is configured to be placed directly into ahigh-temperature cooking apparatus.
 13. The method of claim 1, furthercomprising refrigerating or freezing the package, wherein therefrigerated or frozen package is configured to be placed directly intoa high-temperature apparatus.
 14. The method of claim 1, wherein thepackage is configured to facilitate a reduced cook cycle that is aboutone-hour or less.
 15. A contained package for preparing a ribbed meatproduct in a reduced cook cycle, the contained package comprising: ahigh-temperature cook-in bag comprising a film configured to be exposedto a temperature of at least 350° F. during the reduced cook cycle,wherein the film has an oxygen barrier transmission coefficientapproximately equal to, or less than, 30 cc/24 hr/100 in²/mil and awater vapor barrier transmission coefficient approximately equal to, orless than, 40 g/24 hr/100 in²/mil; and a ribbed meat product sealedwithin the high-temperature cook-in bag.
 16. The contained package ofclaim 15, wherein the film is a blended monolayer film comprising atleast 75% nylon blended with at least one of a polyester, a polyamideelastomer, or a polyester elastomer.
 17. The contained package of claim15, wherein film is a blended monolayer film comprising about 60% to 80%nylon 6 and about 20% to 40% heat-stabilized nylon 6,6.
 18. Thecontained package of claim 15, wherein the film is a multilayer filmcomprising an outer layer and an inner layer, wherein the outer layerincludes at least 75% nylon or polyester blended with a polyesterelastomer or a polyamide elastomer, and wherein the inner layer includesa polyester elastomer or polyamide elastomer.
 19. The contained packageof claim 15, wherein the film is a multilayer film comprising an outerlayer, an inner layer and a tie layer disposed between the outer andinner layers, wherein the tie layer includes at least a portion of thematerials in the inner and outer layers.
 20. The contained package ofclaim 15, wherein the film has a thickness in a range of about 1 mil to6 mils, a tear strength greater than about 50 g/mil, and a tensile yieldstrength of greater than approximately 2,000 psi.
 21. The containedpackage of claim 15, wherein the ribbed meat product is pre-cooked orpre-rendered.
 22. The contained package of claim 15, wherein the ribbedmeat product is hermetically sealed within the high-temperature cook-inbag.
 23. The contained package of claim 15, wherein the containedpackage is configured to be placed directly into a high-temperaturecooking apparatus.
 24. The contained package of claim 15, wherein thecontained package is configured to be refrigerated or frozen thepackage.
 25. The contained package of claim 24, wherein the refrigeratedor frozen package is configured to be placed directly into ahigh-temperature apparatus.
 26. The contained package of claim 15,wherein the reduced cook cycle is less than the cook cycle ofconventional rendering methods by at least a factor of three.